Compact heat exchanger

Abstract

A compact heat exchanger is provided and includes a first manifold defining an inlet for receiving from a component a fluid to be cooled and an outlet for returning the cooled fluid to the component to cool the component. A second manifold is disposed spaced from the first manifold. A core extends between and fluidly communicates with the manifolds and includes hexagonal channels. Each channel is formed by mini-tubes defining respective triangular passages. A cross-section of the core defines an irregular-cross structure. The fluid enters the inlet of the first manifold, makes a first pass through the mini-tubes to the second manifold, makes a second pass through the mini-tubes to the first manifold such that the fluid is cooled across the mini-tubes, exits the first manifold through the outlet, and returns to the component to cool the component. A method of manufacturing the heat exchanger is provided also.

What is claimed is: 
     
         1 . A method of manufacturing a heat exchanger, the manufacturing method comprising steps of:
 fabricating a first manifold defining an inlet configured to receive from a component a fluid to be cooled and an outlet configured to return the cooled fluid to the component to cool the component;   fabricating a second manifold configured to be disposed spaced from the first manifold;   fabricating a core by a process of three-dimensional printing such that the core is configured to extend between and fluidly communicate with the first and second manifolds and includes a plurality of channels each of which is of generally hexagonal cross-section and formed by a plurality of mini-tubes defining respective passages each of which is of generally triangular cross-section, a cross-section of the core defining an irregular-cross structure and the fluid being configured to enter the inlet of the first manifold, make a first pass through the mini-tubes to the second manifold, make a second pass through the mini-tubes to the first manifold such that the fluid is cooled across the mini-tubes, exit the first manifold through the outlet, and return to the component to cool the component;   and configuring the first and second manifolds and core with each other to form the heat exchanger.   
     
     
         2 . The manufacturing method as set forth in  claim 1 , wherein the cross-section of the mini-tubes defines an isosceles triangle. 
     
     
         3 . The manufacturing method as set forth in  claim 1 , wherein the method comprises further a step of depositing a powdered material in a plurality of sequential layers. 
     
     
         4 . The manufacturing method as set forth in  claim 2 , wherein the material includes any of ceramic, metal, plastic, and any combination thereof. 
     
     
         5 . The manufacturing method as set forth in  claim 4 , wherein the method comprises further a step of using laser-sintered powders of metal to generate desired three-dimensional shapes. 
     
     
         6 . The manufacturing method as set forth in  claim 5 , wherein the method comprises further a step of removing unbound powder, thereby resulting in formation of the designed three-dimensional core.